A method for forming a blank of sheet material includes a step of forming a target shape from the blank. The target shape includes a plurality of component structures connected via a common addendum. Each one of the plurality of component structures has a component-shape and a component-boundary. The common addendum extends between the component-boundary of each one of plurality of component structures and connects the component-boundary of each one of the plurality of component structures with a perimeter of the blank. The method minimizes a projected area of the common addendum via adjustment of a position and/or orientation of each of the component structures, thereby reducing a total amount of sheet material required to form the component structures.

The present invention is directed to a dual sided incremental sheet forming apparatus and method for incrementally forming sheet materials such as sheet metal by utilizing opposed primary and secondary forming tool assemblies and a sheet feeding assembly. The primary forming tool assembly includes a rigid tool and the secondary forming tool assembly includes a compressible and resilient backing layer having either a cylindrical or flat configuration. The sheet feeding assembly positions the sheet material between the two forming tools. The rigid tool applies force to one surface of the sheet material while the resilient backing tool applies counter force to the opposite surface of the work piece as it supports the work piece. This dual sided process localizes the forces on the sheet material so that stresses are advantageously controlled to produce accurately formed asymmetric shapes, without the need for expensive dies. The use of a rigid tool with an opposed resilient backing tool both having linear independent motion also avoids potential wrinkling and tearing of the resulting work piece and enables the formation of numerous, highly detained asymmetric products.

A process for forming a sheet metal component. The process includes rigidly clamping a piece of sheet metal to a clamping fixture and plastically deforming the sheet metal to produce a shaped component during a first manufacturing step. The shaped component has a first amount of springback. During a second manufacturing step, a pair of electrodes applies one or more pulses of electrical current at one or more locations on the shaped component while the shaped component is still rigidly clamped to the clamping fixture during. The one or more pulses of electrical current applied to the shaped component provide an electrically-assisted manufactured (EAM) shaped component. The EAM shaped component has a second amount of springback that is less than the first amount of springback.

A method for the individualized adaptation of the shape of components includes providing a basic material for producing the components. Next at least one unifying production method is selected. The components are then produced with a geometrically identical base shape by the unifying production method. Then at least one individualizing production method is selected. Then the shape of the components is adapted to at least two different final shapes by the individualizing production method that is different from the unifying production method. The final shape of each component differs from its basic shape.

A sheet metal system having incremental forming and direct metal deposition, includes a plate. A groove is created in the plate. A direct metal deposition tool is positioned within the groove. A material is deposited by the direct metal deposition tool onto a surface within the groove creating a rib.

An apparatus for forming a metal workpiece having a first surface is described herein. The apparatus includes a trough containing a liquid. The apparatus also includes a support for positioning the metal workpiece in an impact-receiving position. In the impact-receiving position, the first surface is submerged in the liquid. The apparatus includes a driven member for applying multiple impacts to the first surface of the metal workpiece while the metal workpiece is in the impact-receiving position.

To provide a drawing-out tool for sheet metal which is less in failure and excellent in the durability and has excellent handling property by evading generation of trouble in an electric system by shielding dust, metal dust, soil dust or the like from mingling in or attaching to the electric system. The drawing-out tool for sheet metal comprises a center shaft (22); a first operation means (20) provided with a bit (25) arranged to an apex part of the center shaft; a second operation means (30) for pulling-up the first operation means; and an energization mechanism (100) for supplying electric current to the bit are provided. The housing (10) for accommodating the illumination unit (70) and the illumination unit for illuminating a sheet metal surface accommodated in the housing are included.

A device and a method are provided for shaping sheet metal. The device is provided with a plurality of support and clamping elements which are designed to cooperate with one another so as to clamp the sheet metal for a shaping process by mechanically contacting the sheet metal and by holding, orienting, and/or positioning processes. A plurality of actuators are designed to orient and/or position the plurality of support and clamping elements. A controller for the actuators is designed to control the plurality of actuators for adjusting the orientation and/or position of the support and clamping elements.

A machining surface of a die are provided with a pair of inclined surfaces facing each other across a gap and a flat surface interposed therebetween. Each inclined surface includes an inner end portion on a side near the flat surface and an outer end portion on a side farther away from the flat surface. The molding method includes a mounting step of mounting the metal sheet on the die to span both inclined surfaces, and a pressing step of forming a reduced-thickness portion by pressing the metal sheet between the punch and the inclined surfaces of the die. The pressing step includes setting a bottom dead center of the punch to maintain a gap formed between the inner end portion and a surface of the metal sheet facing the inner end portion.

A method is presented. A tool path having planar parallel alternating paths connected by a plurality of curved transitions is generated. A forming tool is driven along the planar parallel alternating paths and the plurality of curved transitions to shape a material into a workpiece.